Aerodynamic fairings for trailers

ABSTRACT

A system and method aerodynamic fairings including a gap fairing. The gap fairing includes multiple panels. The multiple panels are interconnected utilizing connectors to form a half conical shape extending from a front portion of a trailer. The gap fairing also includes supports connected to the multiple panels through support structure of the trailer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/628,083, filed Nov. 22, 2011 entitled AERODYNAMIC FAIRINGSFOR TRAILER, the entire teachings of which are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates generally to trailers, and includes thetype of trailer that is utilized to transport particulate materials.

BACKGROUND

Many particulate materials are conveniently transported by truck,although they may also be transported by railcar, barge or by othermeans. Trucks that are used to transport such materials commonly includea tractor and an attached trailer having a tank or other containermounted thereon. Such trailers may also be loaded on railcars or barges,or a container may be mounted directly on a railcar or barge.

Frequently, these transport containers are referred to as pneumaticcontainers because of the pneumatic method, involving gas orair-entrainment, by which they may be loaded and unloaded. Particulatematerials that are generally transported in pneumatic containers includeagricultural products such as grain, corn kernels, beans, flour, sugar,peanuts and the like, light-weight aggregate products, and intermediateproducts for various industrial uses such as plastic pellets, powders,coke, lime, silica gel, powdered acid resins, rare earth powders,powdered alumina, and so forth.

Pneumatic containers generally include one or more product compartmentsthat are usually cylindrical and/or spherical in shape in order tofacilitate unloading by a method which involves pressurizing thecompartments. Cylindrical or spherical product compartments are alsogenerally easy to completely empty. For example, each productcompartment may be provided with a discharge hopper that may begenerally cylindrical or conical in shape. Each discharge hopper mayhave a material outlet at the bottom and a valve which controls theentry of material into the outlet.

An unloading system may also be provided which includes a blower orother mechanism for pressurizing air or another gas. The blower mayprovide the energy required for unloading the material from thecontainer in the form of compressed air or another gas. For example, oneend of a pressurizing gas conduit may be attached to the blower and theother end to a pressurizing gas inlet in the container. Operation of theblower compresses air or gas to move it through the pressurizing gasinlet into the container, thereby increasing the pressure of the air orgas above the material in the product compartments in the container inorder to assist in discharging material through the hopper outlets. Oneend of a material conveying conduit may also attach to the blower andextend past and connect to each material outlet so that when the productcompartment has been pressurized, air or another gas may be directedinto the material conveying conduit to entrain material passing througheach material outlet and carry it to the discharge end of the conduit.The container may be mounted on a frame which includes the undercarriageof a trailer. The product compartments of the container are generallyenclosed by a sheet metal sheath, although the front of the sheathenclosure usually has a flat or nearly flat face.

It is known to streamline the undercarriage of a box-type trailer.However, the aerodynamic characteristics of a box-type trailer are quitedifferent from those of a pneumatic container trailer.

SUMMARY

One embodiment includes a system and method for aerodynamic fairingsincluding a gap fairing. The gap fairing may include a multiple panels.The multiple panels may interconnected utilizing connectors to form anaerodynamic shape extending from a front portion of a trailer. The gapfairing also includes supports connected to the plurality of panelsthrough support structure of the trailer.

Another embodiment provides a pneumatic container trailer with a gapfairing. The pneumatic container trailer may include a supportstructure. The pneumatic container trailer may also include multiplepanels interconnected to form a substantially half conical shape. Themultiple panels are interconnected utilizing connectors. The pneumaticcontainer trailer may also include supports connected between multiplepanels through the support structure of the trailer.

Yet another embodiment provides a gap fairing. The gap fairing mayinclude multiple panels. The multiple panels are interconnectedutilizing connectors to extend over a support structure of a pneumaticcontainer trailer. The gap fairing may also include supports connectedto the multiple panels that extend through the support structure of thetrailer to secure the multiple panels.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments of the present invention are described indetail below with reference to the attached drawing figures, which areincorporated by reference herein and wherein:

FIG. 1 is a side view of a tractor and a pneumatic trailer in accordancewith an illustrative embodiment;

FIG. 2 is a schematic, pictorial representation of a pneumatic containertrailer with a gap fairing and an undercarriage fairing installed inaccordance with an illustrative embodiment;

FIG. 3 is a schematic, side view of a gap fairing mounted on a pneumaticcontainer trailer in accordance with an illustrative embodiment;

FIG. 4 is a schematic, top view of components of the gap fairing inaccordance with an illustrative embodiment;

FIG. 5 is a schematic, top view of the gap fairing in accordance with anillustrative embodiment;

FIG. 6 is a schematic, front view of the gap fairing in accordance withan illustrative embodiment;

FIG. 7 is a schematic, side view of the gap fairing in accordance withan illustrative embodiment;

FIG. 8 is a schematic, rear view of the gap fairing in accordance withan illustrative embodiment;

FIG. 9 is a schematic, pictorial representation of a pneumatic containertrailer with an undercarriage fairing installed in accordance with anillustrative embodiment;

FIG. 10 is a schematic, frontal pictorial representation of a pneumaticcontainer trailer with an undercarriage fairing installed in accordancewith an illustrative embodiment;

FIG. 11 is a schematic, pictorial representation of an undercarriagefairing in accordance with an illustrative embodiment;

FIG. 12 is a schematic, pictorial representation of an inside view ofsupports of an undercarriage fairing in accordance with illustrativeembodiment;

FIG. 13 is a schematic, pictorial representation of an inside view ofsupports of an undercarriage fairing in accordance with illustrativeembodiment;

FIG. 14 is a schematic, top view of components of the undercarriagefairing in accordance with an illustrative embodiment;

FIG. 15 is a schematic, side view of the undercarriage fairing inaccordance with an illustrative embodiment;

FIG. 16 is a schematic, front view of the undercarriage fairing inaccordance with an illustrative embodiment; and

FIG. 17 is a schematic, bottom view of the undercarriage Faring inaccordance with an illustrative embodiment; and

FIG. 18 is a schematic, pictorial representation of another gap fairingin accordance with an illustrative embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

The illustrative embodiments provide a system, method, fairings, andcomponents for improving the aerodynamic characteristics of a pneumaticcontainer trailer, and thereby reducing dragging and improving the fuelefficiency of the trailer. Field testing shows that the describedembodiments may result in fuel economy improvements as much as seventenths of a mile per gallon. Other advantages and features of theillustrative embodiments are apparent from an examination of thedrawings and the ensuing description.

The illustrative embodiments provide a first and second fairing(“fairings” or “pair of fairings”) for improving the aerodynamiccharacteristics of trailers, such as a pneumatic container trailer. Agap fairing is provided for the front end of the pneumatic containertrailer and an undercarriage fairing is provided for the wheel assembly.The gap fairing may be utilized to improve the aerodynamics of windstriking and being diverted around the front portion of the pneumaticcontainer trailer. The undercarriage fairing may be placed proximate thewheel assembly with components on both sides of the pneumatic containertrailer (just in front of the rear wheels) thereby reducing the drag ofthe wheel assembly and other portions of the pneumatic containertrailer.

The fairings may be positioned, adjusted, and customized to fit trailersof different types (e.g. Super Jet dry bulk and Super Jet trailers) andproduced by different manufacturers (e.g. Heil, J&L Trailers, etc.). Forexample, during installation the fairings may be bent, trimmed, cut,adjusted, or otherwise modified to fit the selected trailer. A personinstalling the trailers may need to accommodate gauges, hoses, storagecomponents, hoppers, suspension, or different frame sizes.

The gap fairings and the undercarriage fairings may be configured to beshipped in flat packages to reduce the shipping price and cost. Forexample, the fairings may be shipped as kits that may be installed onnew or existing trailers to reduce drag and improve fuel efficiency forthe vehicle (e.g. semi-truck, truck, etc.) pulling the trailer. Forexample, the components of the fairings may be shipped on a 4×8 footpallet reducing shipping prices. The fairings may be shipped as modularkits including plastic panels, metal connectors, connection components(e.g. bolts, washers, nuts, fasteners, etc.), and support components(e.g. U-channels, metal brackets, flexible rods, etc.).

In one embodiment, the components of the fairings may be bolted togetherand attached or clamped to existing trailer components. The bolts andother fasteners (e.g. carriage bolt, jam nut fasteners, etc.) maypre-configured to specific thicknesses to secure the components of thefairings without inhibiting the thermal expansion of the plasticcomponents. The fairings may be installed by one or more individualsutilizing hand tools. In one embodiment, the fairings may be fabricated,shipped, and installed in kits that reduce the number of holes ormodifications that are required to the trailer itself.

The fairings may also be easily removed for trailer maintenance orrepairs. In one embodiment, the components of the fairings may includerigid high-density plastic and aluminum to provide strength whilekeeping weight low. The fairings are configured to resist road salts andcorrosion, do not fade or discolor, and are easily cleaned with typicaltrailer wash agents. The fuel savings implemented by installing thefairings generate a significant return on investment with typicalpayback being realized in less than one year. The size and shape of thefairings may vary between different trailer types and manufacturers. Forexample, the panel sizes and connectors may vary to accommodate thedifferent frame, beam, and rail sizes and configurations, trailercomponents, and so forth.

In one embodiment, the panels may have different cut-outs or knock-outbased on the make, model, operator, and configuration of the trailer.The fairings may have a surface (e.g. low affinity for materialadherence) that prevents materials, such as mud, salt, or dust fromadhering to the different components. The fairings may be sold andshipped together or separately based on the needs of the individualoperator. Although the fairings are described as having multiple panels(i.e. front and rear panels for both a left side of the trailer and aright side of the trailer) for an installation kit. In one embodiment,the fairings may include only a left side and right side panel that maybe attached or connected to form the gap fairing or the undercarriagefairing.

The use of the terms “a”, “an”, “the” and similar terms in the contextof describing the invention are to be construed to cover both thesingular and the plural, unless otherwise indicated herein or clearlycontradicted by context. The terms “comprising”, “having”, “including”and “containing” are to be construed as open-ended terms (i.e., meaning“including, but not limited to,”) unless otherwise noted. The terms“substantially”, “generally” and other words of degree are relativemodifiers intended to indicate permissible variation from thecharacteristic so modified. The use of such terms in describing aphysical or functional characteristic of the invention is not intendedto limit such characteristic to the absolute value which the termmodifies, but rather to provide an approximation of the value of suchphysical or functional characteristic.

The use of any and all examples or exemplary language (e.g., “such as”and “preferably”) herein is intended merely to better illuminate theinvention and the preferred embodiments thereof, and not to place alimitation on the scope of the invention. Nothing in the specificationshould be construed as indicating any element as essential to thepractice of the invention unless explicitly so stated. The differentembodiments, features, and description for the fairings may be utilizedin any number of combinations and are not limited to a particularembodiment.

Several terms are specifically defined herein. These terms are to begiven their broadest possible construction consistent with suchdefinitions, as follows:

The term “particulate material” refers to granular, fluent or comminutedmaterial that is capable of being transported through a conduit by anentraining gas. The terms “front”, “forward” and similar terms refer tothe end of a trailer, or a component or portion of a trailer, which isnearest the tractor when the trailer is in use on a highway. The terms“back”, “rearward” and similar terms refers to the end of a trailer, ora component or portion of a trailer, which is farthest away from thetractor when the trailer is in use on a highway. The illustrativeembodiments may be applied to trailers, vehicles, trains, or othermoving apparatuses.

FIG. 1 is a side view of a tractor 12 and a pneumatic container trailer10 in accordance with an illustrative embodiment. FIG. 1 illustrates apneumatic container trailer 10 which is attached to tractor 12. Thetractor 12 represents any number of semi-trucks, tractors, cars, trainsor other vehicles that may pull the pneumatic container trailer 10. Thepneumatic container trailer 10 includes pneumatic container 14 includingfour product compartments that are enclosed by an exterior sheath. Thepneumatic container trailer 10 is representative of any number ofcontainers as utilized in numerous applications or as are described andshown herein. The pneumatic container 14 has a front end 16 and a rearend 18, and is mounted on frame 20 which includes front frame portion 22and undercarriage wheel assembly 23.

FIG. 2 is a schematic, pictorial representation of a pneumatic containertrailer 200 with a gap fairing 202 and an undercarriage fairing 900(jointly the “fairings 201”) installed in accordance with andillustrative embodiment. Each of the fairings 201 may be utilized toreduce drag of the pneumatic container trailer 200 between 3-5%. As aresult, the fairings 201 provide an improved fuel economy to the vehiclepulling the pneumatic container trailer 200.

The fairings 201 provide a system and method of equipping the pneumaticcontainer trailer 100 with fairings 201 that produce the benefits offairings utilized on traditional box or rectangular shaped trailers. Inone embodiment, the components that make up the fairings 201 aremanufactured and shipped as flat or substantially flat components tosignificantly reduce the domestic or worldwide shipping costs.

The fairings 201 may be bent, cut, trimmed, modified, or otherwisepositioned to fit any number of different trailer types that include,but are not limited to, pneumatic or liquid container trailers. Forexample, portions of the fairings 201 may be cut to slip over hoses,tubes, gauges, extensions or so forth. The cut portions may then beconnected back together utilizing metal connectors, brackets, or soforth on one or more internal and external sides of the fairings. As aresult, the fairings 201 are extremely adaptable while still providingenhanced fuel economy. The slope of the gap fairing 202 may also varybased on the height of the pneumatic container trailer 200 components(e.g. storage container) and the length of the front end of thepneumatic container trailer 200. The gap fairing 202 (and correspondingangle) may be positioned between a top of a front head of the front end206 and bottom end. The gap fairing may be adapted to fit any strutframe trailer design.

In one embodiment, the gap fairing 202 is adapted to be attached to afront end 206 of the pneumatic container trailer 200. The gap fairing202 may have a substantially half conical shape (e.g. right circularcone or an oblique circular cone. For example, the gap fairing 202 mayhave a partial conical shape (e.g. envision a cone divided in halfvertically from the vertex in a straight line or at various angles toaccommodate the trailer shape). For example, a bottom portion of thecircle of the cone may have extensions that extend laterally to wrapfurther around the front portion of the pneumatic container trailer 200.The bottom edge of the gap fairing 202 may be positioned against thepneumatic container trailer 200. For example, the bottom edge of the gapfairing 202 (i.e. front or edges that wrap around) may be secured tofront or side gussets, braces, beams, frame, or other support structureof the pneumatic container trailer 200. The support structure of thepneumatic container trailer 200 includes the frame, beams, and otherstructural components of the pneumatic container trailer 200. Theinternal structure of the gap fairing 202 may keep the panels and otherportions of the gap fairing 202 in tension to maintain the desiredpositioning and angles.

Turning now to FIGS. 3-8 illustrating a gap fairing 202 in accordancewith an illustrative embodiment. The gap fairing 202 may be shippedalone or with the described undercarriage fairing as a kit based on theneeds of a user and specifications of a trailer. In one embodiment, thegap fairing 202 may be made up of panels 208, 210, 212, and 214 (jointlythe “panels 215”), such as four flexible plastic parts, and connectors216-226 (jointly the “connectors 227”), such as ten or more metalconnectors (including L-shaped brackets, U-channels, and flat panels).

The panels 215 may also be referred to as cowls because of theirrespective positions and shapes. The panels 208 and 210 may alsoreferred to as front panels and the panels 212 and 214 may be referredto as rear panels based on their relative positioning (this applies tothe other embodiments as well). In another embodiment, the panels 208and 212 may represent a single panel and panels 210 and 214 mayrepresent a single panel.

In one embodiment, the panels 215 are connected together in asubstantially half cone or hemiconical shape. As a result, the gapfairing 202 has a half-conical shape that decreases drag on the othercomponents of the pneumatic container trailer 200. The panels 215 may bebent around or against the support structure (e.g. hose holder, frontframe, front head, container, hopper, etc.) of the pneumatic containertrailer 200 to provide a custom fit.

In one embodiment, the panels 208 and 212 may be approximately 80″ longand approximately 48″ wide. The panels 210 and 214 may be approximately42″ wide and 23.25″ wide. The panels described herein may be formed ofThermoPlastic Olefin (TPO), Acrylontrile Butadiene Styrene (ABS)plastic, flexible polyurethane, thermo-plastic, polycarbonate,polypropylene, rigid polymer alloys, nylon alloys, fiberglass,reinforced polyester, aluminum alloy, or other similar types of plastic,metal, or composites that are strong and lightweight.

The components of the gap fairing are more efficiently shipped andpositioned if they are shipped flat and then subsequently bent intoposition during installation. In one embodiment, the panels 215 may be0.2″ thick. The connectors described herein may be formed aluminum,steel, polymers, or a metal composite and may be approximately 0.125″thick. However, the thickness of the different components may vary basedon application between approximately ⅛″-¼″ or larger in somecircumstances (e.g. increased winds or object strikes are expected).

The components of the gap fairing 202 may be produced or manufacturedwith holes 220 for bolts, washer, and nuts to attach the variouscomponents to each other or to a front frame portion of a pneumaticcontainer trailer 200. For example, a bottom portion of the panels 215adjacent the frame of the pneumatic container trailer may be attached inthe front and/or sides of the frame. For example, matching holes may bedrilled or pre-drilled through the frame, beams, or support structure tosecure the panels 215 in place utilizing bolts and aluminum fastenerplates on one or more sides of the panels 215.

In one embodiment, the panels 215 may be connected utilizing shoulderbolts. The shoulder bolts may have a shaft with a thickness greater thana threaded portion where a nut is screwed on. The shoulder bolts may beutilized to ensure that the panels 215 are not overly tightened onto theframe of the pneumatic container trailer 200 resulting in potentialfailure of the panels 215 or other connectors, such as metallic sheets.The shoulder bolts or other similar fasteners may provide a loose yetsecure connection. In one embodiment, the holes 220 may be slotted toaccommodate the thermal expansion of the panels 215. In one embodiment,panels 208 and 212 may be joined together in the front or exteriorsurface by connector 218 and in the rear or against the interior surfaceby the connector 216.

In one embodiment, the connected panels 208 and 212 are connected togussets of the pneumatic container trailer 200 utilizing any number ofbolts. The panels 208 and 212 may include an angled bracket (not shown)for connecting the panels 208 and 212 to the gussets utilizing bolts.

The panels 210 and 214 are attached to the panels 208 and 212,respectively. In one embodiment, each of the panels 208-214 areinterconnected utilizing connectors 228 and 230, represented as metalstrips. In other embodiments, the panels 208-214 may be connectedutilizing rivets, plastic welding, industrial adhesives, or so forth.

The internal structure of the gap fairing 202 may include one or morehorizontal or diagonal supports. The supports make extend through thestruts and other structural components of the pneumatic containertrailer 200 to stabilize and secure the panels 215 to form the gapfairing 202. In one embodiment, the back side of the gap fairing 202 isconnected to a reinforcing box 228. The reinforcing box 228 may beformed utilizing connectors 220 and 222, shown as metal strips, andconnectors 224 and 226, shown as metal angles. The reinforcing box 228may be attached to panels 210 and 214 and/or through or to a front frameportion of the pneumatic container trailer 200. The reinforcing box 228or associated components provide a tension bearing support to supportthe panels 215 that are bent into shape. In another embodiment, thereinforcing box 228 is replaced may cables, rods, or other tensionedconnectors that extend between the panels 215 to maintain the desiredshape and cohesion of the gap fairing in the event of unforeseencircumstances, such as a wreck, bad weather, strikes, or so forth.

The gap fairing 202 may be connected to the front frame portionutilizing connectors 232 and 234 and any number of other similarconnectors. The gap fairing 202 may be further stabilized utilizingdiagonal supports, such as brackets, connecting rods, or othercomponents. The gap fairing 202 including the panels 215 may be securedby the internal supports including the reinforcing box 228 through thestruts, beams and other components that make up the pneumatic containertrailer 200 itself.

In one embodiment, the gap fairing 202 may only weight 66 pounds, butmay improve fuel economy by as much as four tenths of a mile per gallon.The gap fairing 202 may be positioned at the front of the pneumaticcontainer trailer 200 against, over, adjacent, or extending from thestructural components of the front of the pneumatic container trailer200, such as a hose holder mast (“flag pole”), front frame, and fronthead.

Turning now to FIGS. 9-17, illustrating an undercarriage fairing 900 inaccordance with an illustrative embodiment. As previously described, thecomponents of the undercarriage fairing 900 may be shipped as a kit tobe assembled. The undercarriage fairing 900 may include at least panels902, 904, 906, and 908, front connector 910, front bridge 912,connectors 914, connectors 915, and joints 916. The components of theundercarriage fairing 900 may be pre-drilled or provided with holes forbolting the components to each other and to the undercarriage of theframe of the trailer. When the components are assembled, theundercarriage fairing 900 forms a bell-like shape (see FIGS. 11 and 17)that increases the aerodynamics of the trailer by reducing drag on theundercarriage, frame, rear wheel assembly, and other portions of thetrailer.

In one embodiment, the panels 902 and 904 may be approximately 81″ longand approximately 19″ high at a front end 917 and widened toapproximately 28″ high at a rear end 919. The panels 902 and 904 mayinclude one or more cut-outs including cut-out 903. In one embodiment,the panels 902 and 904 may narrow or taper from the rear end 919 to thefront end 917 to accommodate components, such as a discharge pipe of apneumatic container trailer. In other embodiments, the panels 902 and904 may have a uniform width.

The cut-out 903 may be configured to accommodate the frame 926 of thetrailer. For example, the cut-outs 903 may fit against one or more beamsof the frame 926. The panels 902 and 904 may also have a cut-out cornernear the front end 917 configured to fit over or against the dischargepipe. The panels 902-908 may have any number of cut-outs, knock outs, orholes providing access to different trailer components or allowingtrailer components to extend through the undercarriage fairing 900. Inone embodiment, approximately 6-10″ of clearance is left between thebottom of panels 902-908 and the roadway. However, the clearance mayvary based on the driving environment associated with the trailer.

In one embodiment, the panels 906 and 908 are positioned at thesides/edges of the trailer just in front of the rear wheels and rearwheel assembly. For example, the plane of the panels 906 and 908 may beinwardly angled toward the center of the trailer. The panels 902 and 904come together from the rear end 919 underneath the middle of the trailerto be connected in a front end 917. As a result, the undercarriagefairing 900 may form a wedge, V, or bell shape for cutting through theair to reduce the air drag (see FIGS. 11 and 17). In another embodiment,the panels 902 and 906 may represent a single panel and panels 904 and908 may represent a single panel.

Panels 902 and 904 may be attached or joined together at the front end917 of the undercarriage fairing 900 by the front connector 910 (shownas a V-shaped bracket) and the front bridge 912. For example, the frontconnector 910 may be connected to an exterior surface 918 of theundercarriage fairing 900 and the front bridge 912 may be connected toan interior surface 920 of the undercarriage fairing 900.

In one embodiment, the front bridge 912 may be connected to the panels902 and 904 utilizing any number of bolts, washers, and nuts. The frontbridge 912 may be wider than the front connector 910 to provideadditional stability where connected to the panels 902 and 904. As shownin FIG. 1, the front bridge 912 may extend above a top edge 923 of theundercarriage fairing 900. In one embodiment, the front bridge 912 maybe connected directly to the undercarriage or frame of the trailer. Inanother embodiment, the front bridge 912 may connect to a U-channel thatis also attached to the frame 926 as is subsequently described (e.g.U-channels 922 and 924 connected between elements of the frame).

The front connector 910 may be a metal angled piece with an angleconfigured to bring the panels 902 and 904 together. The front connector910 includes holes that align with holes of the panels 902 and 904 forbolting the components together. In one embodiment, the front bridge 912is a connector with two side flanges for securing to the panels 902 and904 and a vertically extending portion for connecting to the frame 926(e.g. cross beam, support structure) or a U-shaped channel that isclamped horizontally to the frame (as is subsequently described). Thefront bridge 912 may be connected to the undercarriage of the frame ofthe trailer, such as the frame rails, a hopper lip, or so forth. Forexample, the front bridge 912 may extend above a top edge of the panels902 and 904 to connect to the frame 926. The panels 906 and 908 are eachconnected to one of the panels 902 and 904. For example, the panels 906and 908 may be directly connected to the interior surface 920 of thepanels 902 and 904 utilizing carriage bolts.

In one embodiment, the weight of the rear portion 919 of the panels maybe supported by U-channels 922 and 924 that are connected to the frameof the trailer. The joints 916 may be connected to or between thechannels 922 and 924 and to the panels 902 and 904. The joints 916 maybe shipped pre-bent or may be bent or formed when received to fit thetrailer. For example, the joints 916 may be bent to form a lip 913 thatis then connected to the panels 902 and 904.

The U-channels 922 and 924 may be clamped to a frame 926 of the trailer(see FIG. 13) to securely affix and hold the U-channels 922 and 924 andthe undercarriage fairing 900. For example, clamping brackets 928 and930 may be attached to the frame 926 (shown as a beam). The clampingbrackets 928 and 930 may be connected utilizing carriage bolts and nuts,screws, or other attachment components or mechanisms known in the art.In one embodiment, the clamping brackets 928 and 930 may be looselyfitted against the U-channels 922 and 924 while assembling theundercarriage fairing 900 to allow for a custom fit of the frame 926 ofthe trailer.

In one embodiment, the panels 902 and 904 may be further supported byconnecting rods 932 and 934. For example, the connecting rods 932 may beconnected to brackets 934 that are secured to the panels 902 and 904 atone end and to the U-channels 922 and 924 at a second end. In oneembodiment, the connecting rods 932 may be pivotally connected at afirst end to a bottom portion at or near the edge of the panels 902 and904 and at a second end to the U-channel 922 and 924.

As a result, the panels 902 and 904 and connecting rods 932 may bendslightly, move, or reposition in response to striking objects, such astires, rocks, or other roadway hazards. The connecting rods 932 providediagonal supports that support the panels 902 and 904. The ability toflex or move slightly may prevent the undercarriage fairing 900 frombreaking in response to heavy winds, striking objects, or otherunforeseen circumstances. In one embodiment, the connecting rods 932 arefiberglass rods that are configured to receive substantial strikes orimpacts against the panels 902-908 without breaking. As a result, thepanels 902-908 may flex in response to a strike before returning to thedefault installed position.

In one embodiment, the rear portion 919 of the panels 902 and 904 may bepositioned directly in front of the wheel assembly to reduce drag on thewheels, undercarriage and so forth. In one embodiment, the undercarriagefairing 900 adds only about 63 pounds to the weight of the trailer whileincreasing the fuel economy by as much as three tenths of a mile pergallon.

FIG. 18 is a schematic, pictorial representation of another gap fairing1800 installed on a trailer 1801 in accordance with an illustrativeembodiment. The gap fairing 1800 illustrates panels 1802, 1804, 1806,and 1808 (not visible) of different sizes and configurations. In oneembodiment, the panels 1802 and 1804 may extend to be flush with thesupport structure (see FIG. 5). The gap fairing 1800 may not extend allthe way. In another embodiment, the gap fairing 1800 includes anotherpanel (not shown) to further extend the length of the front fairing mainsection created by the panels 1802 and 1804. In yet another embodiment,an additional upper panel or side panels (not shown) may be connected tofurther reduce drag.

The gap fairing 1800 may include a cut-out 1810 for the hose holder1812. In one embodiment, the cutout 1810 may be generated or fabricatedduring the manufacturing process. In another embodiment, the cut-out1810 may be created by a person installing the gap fairing 1800.

The panels 1802 and 1804 when connected by at least connector 1814provide a substantially rectangular shape with a rounded top portion1818. In one embodiment, a top portion of the panels 1802 and 1804 maynearly reach a top portion 1816 of the trailer 1801 to provide effectivedrag reduction.

The panels 1806 and 1808 are substantially triangular shaped andincreased in size over other embodiments. In one embodiment, the panels1806 and 1808 may be connected to side gussets (not shown) that are partof the support structure of the trailer 1801. The panels 1802-1808 maybe configured to be connected utilizing the connectors as are hereindescribed with or without overlapping sections of the panels 1802-1808.

The fairings may be installed by positioning the panels, bending thepanels into shape around the support structure of the trailer,interconnecting the panels to one another, and connecting the panels tothe support structure of the trailer, and further securing the panelsutilizing one or more connectors. The support structure of the trailermay be modified, drilled, or otherwise adapted to receive the fairings.The aerodynamic configuration of the fairings may take any number ofshapes that are customized for the particular trailer.

In one embodiment, the plastic panels (including holes, slots, andcut-outs), connectors, brackets, or support components of the describedembodiments may be automatically cut and drilled using an automaticcutting program and tool. The panels are fabricated, cut, and shippedflat for ease of manufacturing and shipping. The panels are then bentinto position to create an aerodynamic shape for the respective gapfairings and undercarriage fairings.

In one embodiment, the fairings may be installed without cutting ordrilling holes in the trailer or associated frame. In anotherembodiment, the fairings may be installed with minimal holes orstructural modifications to the trailer. For example, the fairings mayclamp onto existing beams, brackets, or structures of the trailer. Inone embodiment, the fairings may have a floating attachment for all or aportion of the components of the fairings such that the attachmentpoints of the fairings may float slightly in response to thermalexpansion, wind, object strikes, or so forth to prevent undue damage.

The drag coefficient of the trailer may be reduced by installing thefairings because of the smooth surfaces provided by the plastic panelsas well as the aerodynamic shapes of the gap fairing and theundercarriage fairing as are herein described and shown. The fairingssubstantially improve the aerodynamic properties of the trailersresulting in significant improvements in fuel economy.

Although this description contains many specifics, these should not beconstrued as limiting the scope of the invention but as merely providingillustrations of the presently preferred embodiment thereof, as well asthe best mode contemplated by the inventor of carrying out theinvention. The invention, as described herein, is susceptible to variousmodifications and adaptations, as would be understood by those havingordinary skill in the art to which the invention relates. The previousdetailed description is of a small number of embodiments forimplementing the invention and is not intended to be limiting in scope.The following claims set forth a number of the embodiments of theinvention disclosed with greater particularity.

What is claimed:
 1. A gap fairing comprising: a plurality of panels,wherein the plurality of panels are interconnected utilizing connectorsto form an aerodynamic extending from a front portion of a trailer; andsupports connected between the plurality of panels through supportstructure of the trailer.
 2. The gap fairing according to claim 1,wherein the trailer is a pneumatic container trailer, and wherein abottom portion of the plurality of panels is connected to the supportstructure of the trailer.
 3. The gap fairing according to claim 1,wherein components of the gap fairing including the plurality of panelsand the supports are shippable as a flat package.
 4. The gap fairingaccording to claim 1, wherein the plurality of panels form a halfconical shape and include at least four plastic panels.
 5. The gapfairing according to claim 1, wherein a bottom edge of the plurality ofpanels is positioned against the support structure of the trailer. 6.The gap fairing according to claim 1, wherein the supports are connectedto the plurality of panels by connectors utilizing carriage bolts with adefined separation to support thermal expansion of the plurality ofpanels.
 7. The gap fairing according to claim 1, wherein the connectorsinclude metal strips for connecting the plurality of panels.
 8. The gapfairing according to claim 1, wherein the plurality of panels includesat least two front panels that are interconnected, and at least two rearpanels that are connected to each of the at least two front panels. 9.The gap fairing according to claim 1, wherein the supports form areinforcing box that extend through the support structure of thetrailer.
 10. The gap fairing according to claim 1, wherein the pluralityof panels are bent into shape.
 11. A pneumatic container trailer with agap fairing, comprising: the pneumatic container trailer including asupport structure; a plurality of panels interconnected to form asubstantially half conical shape, wherein the plurality of panels areinterconnected utilizing connectors; and supports connect the pluralityof panels through the support structure of the trailer.
 12. Thepneumatic container trailer according to claim 11, wherein the pluralityof panels include at least four plastic panels that are positionedaround the support structure to enhance aerodynamics of a front portionof the trailer and wherein a bottom portion of the plurality of panelsis connected to the support structure.
 13. The pneumatic containertrailer according to claim 12, wherein the supports are connected to theplurality of panels by connectors utilizing carriage bolts with adefined separation to support thermal expansion of the plurality ofpanels.
 14. The pneumatic container trailer according to claim 12,wherein components of the gap fairing including the plurality of panelsand the supports are shippable as a flat package.
 15. The pneumaticcontainer trailer according to claim 11, wherein the supports form areinforcing box that extend through the support structure of thetrailer, and wherein the plurality of panels are bent into shape.
 16. Agap fairing comprising: a plurality of panels, wherein the plurality ofpanels are interconnected utilizing connectors to extend over a supportstructure of a pneumatic container trailer; and supports connected tothe plurality of panels extend through the support structure of thetrailer to secure the plurality of panels.
 17. The gap fairing accordingto claim 16, wherein one or more of the plurality of panels are modifiedto fit the support structure of the pneumatic container trailer.
 18. Thegap fairing according to claim 16, wherein the supports include one ormore horizontal supports or diagonal supports connected between theplurality of panels and wherein a bottom portion of the plurality ofpanels is connected to the support structure of the trailer.
 19. The gapfairing according to claim 16, wherein the plurality of panels form arounded aerodynamic shape for a front portion of the pneumatic containertrailer.
 20. The gap fairing according to claim 16, wherein theconnectors are connected to the plurality of panels utilizing bolts witha defined separation to support thermal expansion of the plurality ofpanels.